Process for the constructive conversion of heavy to light hydrocarbons



W. E. SHORE PROCESS FOR THE CONSTRUCTIVE CONVERSION OF HEAVY TO LIGHT HYDROCARBONS Oct. 16, 1928. 1,687,595

Filed Dec. 26, 1925 [n #6 n ion y M v M? Patented Oct. .16, 1928.

UNITED STATES.

E. SHORE, 01' NEW YORK, N. Y. 7

raocass iron man oonsrauc'rrva' conv'ansron or HEAVY TO men'r nxnaocannon's.

Application filed December 28, 1923. Serial No. 682,602.

The principal objects of this invention are, to efi'ect the production of the maximum percentage of hydrocarbons of a low boiling point from hydrocarbons of a highrboiling point, and to accomplish such result in an economical manner.

Many different methods of conversion of hydrocarbons have been evolved such as distillation, cracking, catalyzing, or by spraying into gases, etc., many of which .are more or less destructive. a The present process pro oses a constructive conversion, the principa feature of which consists in atomizing or foggin the heavy hydrocarbons in association wit hydrogen or hydrogen-bearing gases, and subjecting the mixture to mechanical andinternal heat en.- er associating the mixture with hydrogen or ydrogen-bearing gases to produce vapors, which vapors are maintaine in suspension throughout the process.

The accompanying drawing is a diagrammatic View ilustrat ng a suitable arrangement of ap aratus for carrying this invention into e eet.

It isthe purpose of this invention to apply mechanical energy to break up or atomize the oil in the presence of-hydrogen or hydrogenbearing gases or vapors and to produce interbut thoroughly mixing therewith and uil nal heat in this as as the carr ing medium for the hydrocar on, the heat om the heat carrying mediumbeing given up to the hydrocarbon; the entire-mass being moved at high velocity through a system 0 pipes to a compressor, wh'ere final conversion takes place; preserving throughout a maximum heat energy, derived from mechanical energy for the purpose ofmaintaining or increasing the heat of the substances to be converted.

A prime mover for the system is illustrated in the form of atwo cycle engine 1 which is shown directly connected with *a reciprocating compressor 2. Power from the engine is transmitted in a suitable manner to a high speed'rotary pump 3which is of the type havin a rotor eccentrically arranged in a cylinserand provided with vanes engaging the cylinder wall.

The oil to be treated is stored in a tank 4, and is pumped from said tank by a suitable form of circulating pump 5 through the pipe 5' to the jacket 6 surroundin the cylinder of the oil engine so that the radiated heat of the engine cylinder will. be absorbed thereby? The heated oil is conducted-from the jacket 6 of the oil engine through the pipe 6.to the jacket 7 of the compressor 2, absorbing the radiated heat of the compressor. From the jacket 7 the oil is conveyed by the pipe 8 to the top of a suitable expansion reservoir 9, which is preferably provided with a dome 10, so that any volatiles separating therefrom will be carried through a pipe 11, which contains a suitable ressure regulator 12, and is directed in to the feed pipe 13 to the compres'sor cylinder.

A pipe 14 leads from the bottom of the reservoir 9 and extends through the heater 15, which is heated by the exhaust from the engine 1.

The'flow of oil through the pipe14 is governed by a valve 16 leading to theintake conduit 17 to the rotary pump 3. This conduit 17 has connected to it several conduits which are adapted to convey the aforesaid gases to the pump 3 to assist in expanding and atomizin the oil. The use 0 hydrogen or hydrogen-bearmg gases for mixingwith the oil is'advisable,'as the hydrogen aids in subdividing or atomizing the heavy liquid hydrocarbons, the process consisting notonly in-efiecting a physical change by expanding and atomlzing the oil in the suction chamber of the rotary um ing up'the volume with a hydrogen bearing vapour, and it is because of this means that term my method a constructive conversion. A finely atomized condition is best effected in the presence ofair or hydro en or a hydrogen containing gas and the efl ct is two-fold. It not only-aids in the atomizing, but under the pressure and at the temperature and velocity described, the minute mechanically subdivided particles are in a state of molecular 5 instability and due to this state of molecular instability, a chemical combination as well as a physical change takes place gradually and progressively without the aid of a catalyst between the oil and the hydrogen present in 1 the hydrogen-bearing gas, in which the oil particles are suspended.

The speed of the reaction is controlled by the temperature, velocity, pressure and other physical conditions present in each particular 5 stage of the process, and the most complete by rogenation taking place at the last stage, or in the cylinder of the compressor, where it is subjected to the highest temperature conditions;

distinction to destructive conversion,

This process maybe correctly termed a constructive conversion process, in continas 1 lustrated in.- cracking processes, where the ratio of hydrogen to carbon is increased by precipitating the excess carbon. It may be readily seen that in this process the hydrocarbon is actually brought into chemical combination with the enveloping hydrogen, thereby increasing the yield of low boiling point fractions.

The gases are introduced in desirable proportions through the intake conduit 17 and through theoperation of the atomizer pump 3, the mixture of gas and oil is first expanded in the suction chamber of the pump and then it is compressed in the discharge end, the air or other as acting as the expanding, compressing and carrying medium, transferring the heat resulting from mechanical energy to all the molecules of the hydrocarbons.

This condition may be assisted by a suitable jacketing of the atomizing pump, which is here shown with a hollow jacket 18. This I jacket is preferably maintained at a uniform temperature b the circulation of a mercury vapour theretlirough. The vapour may be produced byany suitable form of heater, but the heater is here shown in the form of a jacket 19 surrounding a receptacle 20 whichis connected with the bottom of the jacket 18. by the pipe 21. The exhaust gases pass from the heater 15 through the conduit 19 to the jacket 19. Y

A pipe 22 leads from the top of the receptacle 20.to the top of the pump jacket 18.

The atomized mixture, discharged from the atomizer pump 3, is conducted through a coil 23 arranged in the heater 15, and the temperature of the mixture is raised therein by. heat exchange with the exhaust gases of the engine. It is then conducted through a pipe 24; leading from the bottom end of the coil 23 to a coil 25 arranged within a drum 26.

The terminal end of the coil 25 leads to a similar coil Within a drum 27, and the continuation of this coil leads through a pipe 28 to a coil in a third drum 29, from whence the vaporized mixture, which is being continuously raised in temperature in passage through the coils, is conducted through the pipe 30 to the valve chest and cylinder of the compressor 2.

The temperature of the vaporized mixture in its passage from the atomizer pump 3 to the compressor is raised from approximately 250 F. to approximately 400 F., and when subjected to the operation of the compressor its temperature is again raised to from 8009 F. to 1200 F. This is an essential part of the process that cannot be over emphasized as the mechanical energy of the compressor is transformed into additional heat energy produced by the compression of the mixture, and this heat energy is uniform so on progressively throughout the mixture and acts uniformly upon every particle, thus increasing the molecular instability of the hydrocarbon, and thereby increasing the capacity of the hydrocarbon molecules to combine with additional hydrogen, which combination is completed as the compression is carried out, thereby accomplishing the complete conversion to a lighter hydrocarbon. The highly vaporized mixture then passes through the conduit 31 to andthrough a series of drums 29, 27 and 26. The heat from this mixture in the said drums effects the raising of the temperature of the va ours, passing from the atomizing pump 3 t rough the conduits 25, 28 and 30 to the compressor.

A volatile vapour is conducted from the drum 26 to a series of expansion condensers 32, 33, and 34:, wherein the diiferent gravities of fluid are absorbed. Each condenser is filled with hydrocarbon of the gravity of the fluid to be absorbed in that condenser. The hydrocarbon vapors under pressure are first conducted through the expansion valve 32 where they undergo free expansion with a consequent drop in pressure and teinperature. The hydrocarbon vapour is then conducted through a tube 33 into the hydrocarbon fluid in the condenser 32 and the vapour then asses upward through the condensing liqui hydrocarbon, with the result that all of the vapour which is of the specific gravity of the condensing liquid is absorbed thereby,

and the lighter hydrocarbons pass thence to the next expansion valve and condensing chamber 33 which contains liquid hydrocarbon of a lighter density with consequent similar absorption of the next lighter oil, and

throu h the various controlling valves and con ensers, filled with liquid hydrocarbons of increasingly lighter density, until all the oondensible vapours are condensed. The pressurewithiri the various condensing cham ers being governed in successive stages by the settin of the expansion valves 32 whereby the voume of flow into each of the condensing chambers and consequently the pressure therein may be determined.

The condensing liquids in each condenser will be maintained at the temperature below the condensation temperature of the vapours to be therein condensed by cooling with a water jacket. The hydrocarbons absorbed in the several condensers are carried to the receivers 35, 36 and 37 respectively.

A portion of the converted hydrocarbon vapour flowing from the drum 26 may be conducted through a pipe 38 back to the intake conduit 17 otthe atomizer pump 3, to pass again through the cycle as described, when it is deemed desirable.

A pipe 39 is connected to the top of the final condenser and leads to the intake conduit 17 so that any uncondensed hydrogen-bearing gases and vapours can be passed back through the system. 7

The high temperature oil vapour taken,

from the compressor and circulated through the expanding heating drums 29', 27 and 26 form a certain amount of condensate and this is conducted to a residual receiver 40- through the pipe connections 41 and 42. Provision 1s also made to carry off any condensation of oil particles in the atomizer pump 3 in the form of an oil trap 43 connected with the bottom of the atomizer pump 3 by a pipe 44, any condensed oil is carried back to the intake conduit 17 by a pipe 45.

The suction of the intake effects the evacuation of the oil from the trap 43.

In a process such as described it has been found that crude-oils of either asphaltum or paraflin base may be combined in varyingproportions with hydrogen containing gases by utilizing such gases as a medium for atomizingor disintegrating the heavy oils into a va porous state, and 'these atomized heavy oils are maintained in suspension in the hydrogenbearing gasesby the internal heat of-applied mechanical energy, such as has been described in addition to the heat absorbed from the exhaust from the engine. The results obtained are dependent uponthe speed of movement that is maintained throughout the process. Further, the rapidity of movement of thevapours is such that the percentage of heat fralnsference to surounding bbdies is extreme- Y OW? It is to be noted that throughout the process all material heat transference taking place is preserved within the system and is not lost to outside surrounding bodies, such as water cooled jackets or atmosphere, but the heat developed in one phaseis conserved in the other; for instance, the heat of combustion in the engine is conserved in the passing of the oil through the surrounding jacket, likewise the heat of compression in the compressor is transferred to the oil, which heated oil is later carried to the cylinder of said compressor.

In efiect the process is carried out with a minimum loss of heat of the mechanical 3 energy expended. no

A process such as described is a distinct advance over the processes at present employed, such as distillation and cracking, as in both such s stems the entire mass of the oil being treate is not subject to uniform conditions, whereas with the present process the hydrogen-bearin gases are intimately associated and intermlxedwith thehydrocarbonparticles fromthe commencement of the process in the atomizing pump 3; and at every stage of, this bon molecules, until the combination of the hydrocarbon with its enveloping hydrogen is consummated in the compressor, with a minimum of residuals. y

- What I claim as my invention is 1. A process for converting heavy hydrocarbons to light hydrocarbons, comprising directingtheoil through the jacket of a compressor, then introducing same in the presence of hydrogen bearing gases to -a mechanically operating atomizer, then conducting the 7 produced vapour to the compressorcylinder and raising its temperature-under compression, then passing the highly heated vapour to expansion condensers.

2. A process for converting heavy hydrocarbons to light hydrocarbons, comprising directing the oil through the jacket of a compressor, then introducing same in the presence of hydrogen bearing gases to a mechanically operating atomizer, then conducting the produced vapour through heating coils, then compressing the heated vapour to a high temperature, then circulating the highly heated vapour through expansion drums enclosing said heating coils, and finally passing the vapour to a series of expansion condensers.

3. A process for convertmg heavy hydrocarbons to llght hydrocarbons, comprising passing the oil through the acket of an engine carbons to light hydrocarbons, comprising passing the oil through the jacket of an en gine operating a compressor and an atomizer to absorb the excess heat, then passing it through the jacket of the compressor, then conducting it through a heater heated by the exhaust from the engine, then introducing same in the presence of hydrogen bearing gases to the atomizer, then passing the produced vapour through said exhaust heater, then conducting the ex anded va ur through a series of heated cells, then con netin the superheated vapour to the compressor cy inder compressing same to a high temperature, then conducting said compressed vapour around said heated coils, then expanding the compressed vapour and condensing same in stages. i

5. A process for converting heavy hydrocarbons to light hydrocarbons comprising forcing a continuous flow of oil through an engine cylinder jacket to and through a comfirst subdividing the hydrocarbons in the p presence of supporting hydrogen-bearing gases, passing the said mixture at high velocity through an orifice to a mechanically operated periodically enlarged heated chamber, then compressing and discharging the mixture against a substantially continuous pressure flow, then conducting said mixture through varying heat transference zones progressively increasing the temperature of the mixture under a continued pressure flow, then further compressing said "mixture to cause a further increase in temperature uniformly throughout the mixture thereby progressively increasing the molecular instability of the hydrocarbons receiving the hydrogen until conversion is completed, then conducting the converted mixture to expansion conditions dropping in successive stages the temperature and pressure, then condensing the hydrocarbon vapours into the various gravities of hydrocarbons by passi the condensible hydrocarbons through hy rocarbon liquids in stages of varying gravity.

7. A process for converting heavy hydrocarbons to lighter hydrocarbons com rising first subdividing the heavy hy rocar on in association with and in suspension in hydrogen or hydrogen-bearing gases, then moving the mixture at a high velocity through an orifice to a sealed periodically enlarged heating chamber expanding the suspension medium enveloping the heavy hydrocarbon particles, then compressing same producing internal heat uniformly among the suspended molecules of hydrocarbon and the hydrogen-bearing gases, then discharging under a pressure flow producing molecular instability in the hydrocarbon particles and utilizing the internal heat energy to start the. combining of the hydrogen with the hydrocarbon, then passing the mixture through a heat exchange vaporizing the lighter hydrocarbons and uniting hydrocarbon vapours with hydrogen to produce a lighter hydrocarbon vapour, then further compressing the vapour producing pressure and temperature by mechanical energy, the hydrogen-bearing gases and the formed hydrocarbon vapours acting as the further carrying medium for the hydrocarbon, then giving up this internal heat from this carrying medium to the hydrocarbons circulated around the compression chamher producingin thema. chemical reaction;v

then passing the converted hydrocarbon mass throu h progressive stages'of condensation.

8. 5 process for converting heavy hydrocarbons to light hydrocarbons comprising in forcing a continuous flow of oil through an engine cylinder jacket to and through a com pressor jacket to a mechanical atomizer, mmin therewith hydro en bearing gases and de ivering an atomiz vapour at h1gh velocity through a series of heater coils to a compressor operated by said engine, then exc ending the compressed vapour at lugh velocity through a series of drums, said drums enclosing the heater coils leading to the compressor, and finally conducting the vapour through a series of condensers.

9. An apparatus for converting heavy hydrocarbons to light hydrocarbons comprising, an internal combustion engine having its cylinder jacket connected with an oil supply, a pump for circulating the oil through said jacket, a compressor operated by said engine and having its cylinder jacket connected with the engine cylinder jacket, a heat acketed mechanical atomizer having its intake connected with the compressor jacket, means for'introducing gases to said atomizer with the oil. means for conducting the vapour from the atomizer to the compressor, means for expanding said compressed vapour, and 95 means for condensing the expanded vapour in stages.

10. An apparatus for converting heavy hydrocarbons to light hydrocarbons comprising, an internal combustion engine having its 1 0 cylinder jacket connected with an oil supply,

a pump for circulating the oil through said jacket, a compressor operated by said engine and having its cylinder jacket connected with the engine cylinder jacket, a heat jacketed 10a mechanical atomizer having its intake con- 'nected with the compressor jacket, means for introducing gases to said atomizer withthe oil, an ex aust heater connected with the engine exhaust, means for conducting the vapour from the atomizer through said heater, heater coil conducting said vapour to the compressor, drums enclosing said heater coils and connected in series with said compressor, and expansion condensers arranged in series and connected with said drums- 11. An apparatus for converting heavy hydrocarbons to light hydrocarbons comprising. an internal combustion engine having its cylinder jacket connected with an oil supply. a pump for circulating the oil through said jacket, a compressor operated by said engine and having its cylinder jacket connected with the engine cylinder jacket, a heat jacketed heater coils conducting said vapour to the compressor, drums enclosing said heater coils and connected in series with. said compressor, expansion condensers arranged in series and connected with said drums, and means for conducting heated vapours from said drums 'to theintake of the atomizer.

12. An apparatus for converting heavy hydrocarbons to light hydrocarbons comprising, an internal combustion engine having its cylinder jacket connected with an oil supply, a pump for circulating the oil through said jacket, a compressor operated by said engine and having its cylinder jacket connected with the engine cylinder jacket, a heat WILLIAM E. SHORE. 

